Wacker Neuson PSR1 500 User manual

Operator’s Manual

Pump

PSR1 500

Type PSR1 500

Document 5000187971

Date 1115

Revision 03

Language EN

5000187971

Copyright notice

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the

machine. Any other type of reproduction is prohibited without express

written permission from Wacker Neuson Production Americas LLC.

Any type of reproduction or distribution not authorized by Wacker

Neuson Production Americas LLC represents an infringement of valid

copyrights. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their

respective owners.

Manufacturer

Wacker Neuson Production Americas LLC

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

Original instructions

This Operator’s Manual presents the original instructions. The original

language of this Operator’s Manual is American English.

PSR1 500 Foreword

wc_tx002042gb.fm 3

Foreword

SAVE THESE INSTRUCTIONS—This manual contains important instructions for

the machine models below. These instructions have been written expressly by

Wacker Neuson Production Americas LLC and must be followed during installation,

operation, and maintenance of the machines.

Machines

covered in

this manual

Machine

documentation

 From this point forward in this documentation, Wacker Neuson Production

Americas LLC will be referred to as Wacker Neuson.

 Keep a copy of the Operator’s Manual with the machine at all times.

 Use the separate Parts Book supplied with the machine to order replacement

parts.

 Refer to the separate Repair Manual for detailed instructions on servicing and

repairing the machine.

 If you are missing any of these documents, please contact Wacker Neuson to

order a replacement or visit www.wackerneuson.com.

 When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

Expectations

for

information in

this manual

 This manual provides information and procedures to safely operate and

maintain the above Wacker Neuson model(s). For your own safety and to

reduce the risk of injury, carefully read, understand, and observe all instructions

described in this manual.

 Wacker Neuson expressly reserves the right to make technical modifications,

even without notice, which improve the performance or safety standards of its

machines.

 The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson reserves the right to change

any portion of this information without notice.

Manufacturer’s

approval

This manual contains references to approved parts, attachments, and

modifications. The following definitions apply:

 Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

 Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker

Neuson.

 Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following

consequences:

 Serious injury hazards to the operator and persons in the work area

Machine Item Number

PSR1 500 0620411

Foreword PSR1 500

4 wc_tx002042gb.fm

 Permanent damage to the machine which will not be covered under warranty

Contact your Wacker Neuson dealer immediately if you have questions about

approved or unapproved parts, attachments, or modifications.

wc_bo5000187971_03TOC.fm 5

Table of ContentsPSR1 500

Foreword 3

1 Safety Information 7

1.1 Signal Words Used in this Manual ....................................................... 7

1.2 Machine Description and Intended Use ............................................... 8

1.3 Operating and Electrical Safety ............................................................ 9

1.4 Service Safety .................................................................................... 10

1.5 Labels ................................................................................................. 11

2 Lifting and Transporting 12

3 Installation 13

3.1 Components ....................................................................................... 13

3.2 Preparing the Machine for First Use ................................................... 14

3.3 Application Area ................................................................................. 14

3.4 Preparing for Installation .................................................................... 15

3.5 Checks to Make Before Installation .................................................... 16

3.6 Electrical Wiring .................................................................................. 16

3.7 Connecting the Power Supply ............................................................ 17

3.8 Cable Assembly ................................................................................. 18

4 Operation 19

4.1 Before Starting ................................................................................... 19

4.2 Operating Water Level ..................................................................... 21

4.3 Emergency Shutdown Procedure ....................................................... 21

5 Maintenance 22

5.1 Periodic Maintenance Schedule ......................................................... 22

5.2 Maintenance and Inspection .............................................................. 23

5.3 Storage ............................................................................................... 23

5.4 Disassembly and Reassembly ........................................................... 25

5.5 Disassembly ....................................................................................... 26

5.6 Reassembly ........................................................................................ 27

5.7 Troubleshooting .................................................................................. 28

6 wc_bo5000187971_03TOC.fm

Table of Contents PSR1 500

6 Technical Data 29

6.1 Standard Specifications .......................................................................29

6.2 Operating Specifications .....................................................................30

6.3 Dimensions .........................................................................................30

7 Schematics 31

8 AEM Safety Manual 33

PSR1 500 Safety Information

wc_si000248gb.fm 7

1 Safety Information

1.1 Signal Words Used in this Manual

This manual contains DANGER, WARNING, CAUTION, NOTICE, and

NOTE signal words which must be followed to reduce the possibility

of personal injury, damage to the equipment, or improper service.

NOTICE: Used without the safety alert symbol, NOTICE indicates a

situation which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

This is the safety alert symbol. It is used to alert you to potential personal hazards.

f Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death

or serious injury.

f

To avoid death or serious injury from this type of hazard, obey all safety messages that

follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in

death or serious injury.

f

To avoid possible death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in

minor or moderate injury.

f

To avoid possible minor or moderate injury from this type of hazard, obey all safety

messages that follow this signal word.

Safety Information PSR1 500

8 wc_si000248gb.fm

1.2 Machine Description and Intended Use

This machine is a submersible water pump. The Wacker Neuson

Submersible Pump consists of an electric motor, an impeller, a strainer,

and a metal casing with ports for water suction and discharge. Power is

supplied to the pump through a corded plug or a hard-wired connection,

depending on the installation. The operator connects hoses to the pump

and routes them so that water is pumped from the work area and

discharged into an appropriate location.

This machine is intended to be used for general de-watering applications.

This machine is intended for the pumping of clear water, or water

containing solids up to the size stated within the products specifications,

and up to the flow, head, and suction lift limits also stated within the

product specifications.

This machine has been designed and built strictly for the intended use

described above. Using the machine for any other purpose could

permanently damage the machine or seriously injure the operator or other

persons in the area. Machine damage caused by misuse is not covered

under warranty.

The following are some examples of misuse:

• Pumping flammable, explosive, or corrosive fluids

• Pumping hot or volatile fluids that result in pump cavitation

• Operating the pump outside of product specifications due to

incorrect diameter hoses, incorrect length hoses, other inlet or

outlet restrictions, or excessive suction lift or head

• Using the machine as a ladder, support, or work surface

• Using the machine to carry or transport passengers or equipment

• Operating the machine outside of factory specifications

• Operating the machine in a manner inconsistent with all warnings

found on the machine and in the Operator’s Manual.

This machine has been designed and built in accordance with the latest

global safety standards. It has been carefully engineered to eliminate

hazards as far as practicable and to increase operator safety through

protective guards and labeling. However, some risks may remain even

after protective measures have been taken. They are called residual

risks. On this machine, they may include exposure to:

• Electric shock from improper electrical connections or high

voltage

• Personal injury from improper lifting techniques

• Projectile hazard from discharge

PSR1 500 Safety Information

wc_si000248gb.fm 9

To protect yourself and others, make sure you thoroughly read and

understand the safety information presented in this manual before

operating the machine.

Operator qualifications

Only trained personnel are permitted to start, operate, and shut down

the machine. They also must meet the following qualifications:

• have received instruction on how to properly use the machine

• are familiar with required safety devices

The machine must not be accessed or operated by:

•children

• people impaired by alcohol or drugs

Personal Protective Equipment (PPE)

Wear the following Personal Protective Equipment (PPE) while

operating this machine:

• Close-fitting work clothes that do not hinder movement

• Safety glasses with side shields

• Hearing protection

• Safety-toed footwear

Replacement parts

When replacement parts are required for this machine, use only

Wacker Neuson replacement parts or those parts equivalent to the

original in all types of specifications, such as physical dimensions,

type, strength, and material.

1.3 Operating and Electrical Safety

To reduce risk of electric shock, connect only to a properly grounded,

grounding-type receptacle.

Risk of electric shock—this pump has not been investigated for use in

swimming pool areas.

An acceptable motor-control switch shall be provided at the time of

installation according to local codes and regulations.

To reduce risk of electric shock, follow instructions in this manual for

proper installation.

CAUTION: This pump may automatically restart. Prior to working on

the pump or control panel, all supply circuits must be disconnected.

CAUTION: Risk of shock—do not remove cord and strain relief.

WARNING

Safety Information PSR1 500

10 wc_si000248gb.fm

1.4 Service Safety

Service training

Before servicing or maintaining the machine:

• Read and understand the instructions contained in all manuals

delivered with the machine.

• Familiarize yourself with the location and proper use of all

controls and safety devices.

• Only trained personnel shall troubleshoot or repair problems

occurring with the machine.

• Contact Wacker Neuson for additional training if necessary.

When servicing or maintaining this machine:

• Do not allow improperly trained people to service or maintain the

machine. Personnel servicing or maintaining the machine must

be familiar with the associated potential risks and hazards.

Personal Protective Equipment (PPE)

Wear the following Personal Protective Equipment (PPE) while

servicing or maintaining this machine:

• Close-fitting work clothes that do not hinder movement

• Safety glasses with side shields

• Hearing protection

• Safety-toed footwear

In addition, before servicing or maintaining the machine:

• Tie back long hair.

• Remove all jewelry (including rings).

Replacing parts and labels

• Replace worn or damaged components.

• Replace all missing and hard-to-read labels.

• When replacing electrical components, use components that are

identical in rating and performance as the original components.

• When replacement parts are required for this machine, use only

Wacker Neuson replacement parts or those parts equivalent to

the original in all types of specifications, such as physical

dimensions, type, strength, and material.

PSR1 500 Safety Information

wc_si000248gb.fm 11

1.5 Labels

A nameplate listing the model number, item number, revi-

sion number, and serial number is attached to each unit.

Please record the information found on this nameplate so it

will be available should the nameplate become lost or dam-

aged. When ordering parts or requesting service informa-

tion, you will always be asked to specify the model number,

item number, revision number, and serial number of the

unit.

CAUTION

Do not attempt to operate this product before reading the

Operator’s Manual and understanding its contents.

Mishandling of this product may result in explosion, fire, or

electrical shock.

 Do not pull on the power cord or use the power cord to lift

the pump.

 Always use a dedicated ground leakage circuit breaker.

 Be sure to install the ground wire securely.

 Be sure to disconnect the power supply before handling

or inspecting the pump.

Never insert your hand into the pump inlet holes while the

pump is connected to the power supply.

Menomonee Falls, WI 53051 USA

Model Item No. Rev.

Serial No.

VHz

kWkgMax. L/minMax. m

HPlbsMax. GPMMax.

ft

CUS

L

I

S

T

E

D

R

Phase

C22.2 No. 108-M89

2001993

Conforms to UL Std. 778

Cert. to CAN/CSA Std.

Amp.

Man. Y/

M

THERMALLY PROTECTED

INDOORS OR OUTDOORS

CSA ENCLOSURE

3

Wacker Neuson Corporation

Lifting and Transporting PSR1 500

12 wc_tx001963gb.fm

2 Lifting and Transporting

Do not under any circumstances install or move the pump by

suspending it from the cable assembly. The cable may be damaged,

causing electrical leakage, shock, or fire.

When installing the pump, pay close attention to its center of gravity

and weight. If it is not lowered into place correctly, it may fall and be

damaged or cause injury.

When transporting the pump by hand, be sure to employ manpower

commensurate with the weight of the pump. To avoid back injury when

lifting the pump, bend the knees to pick it up rather than bending your

back only.

Avoid dropping the pump or other strong impact. Lift the pump by

holding it firmly with the hands or by attaching a rope or chain to the

handle.

WARNING

CAUTION

PSR1 500 Installation

wc_tx001978gb.fm 13

3 Installation

3.1 Components

Ref. Description Ref. Description

1 Lifting handle 11 Shaft sleeve

3 Oil lifter 12 Oil casing

4 Oil plug 13 Wear ring

5 Suction cover 14 Impeller

7 Cable assembly 15 Pump casing

8 Mechanical seal 16 Swing check valve

9 Lubricant 17 Bottom plate

10 Discharge outlet 18 V-ring

19 Stand

Installation PSR1 500

14 wc_tx001978gb.fm

3.2 Preparing the Machine for First Use

When the pump is delivered, first perform the following checks:

• Inspection

While unpacking, inspect the product for damage during shipment, and

make sure all bolts and nuts are tightened properly.

• Specification check

Check the model number to make sure it is the product that was

ordered. Be certain it is the correct voltage and frequency.

Note: If there is any problem with the product as shipped, contact your

nearest dealer or Wacker Neuson representative at once.

• Product specifications

Do not operate this product under any conditions other than those for

which it is specified. Failure to observe this precaution can lead to

electrical shock, current leakage, fire, water leakage or other

problems.

3.3 Application Area

If the pump is used for outdoor fountains, garden ponds and similar

places, or to drain a swimming pool, the pump must be supplied by an

isolating transformer or connected to a Residual Current Device (RCD)

with a residual operating current not exceeding 30 mA.

The pump must not be used when people are in the water.

Leakage of pump lubricants may cause pollution of water.

Proper plug must be provided according to local codes and standards.

Refer to wiring diagram.

Do not use this pump in liquids other than water, such as oil, salt water,

or organic solvents.

Use with a power supply voltage within ±5% of the rated voltage.

Do not use in water temperatures outside the range of 0–40°C

(32–104°F) which can lead to failure, electrical leakage or shock.

Do not use in the vicinity of explosive or flammable materials.

Use only in fully assembled state.

Note: Consult your local dealer or Wacker Neuson representative

before using with any liquids other than those indicated in this manual.

3.3.1 Install the pump in a location with sufficient water level, where water

collects readily.

CAUTION

WARNING

PSR1 500 Installation

wc_tx001978gb.fm 15

Note: See “Operating Water Level” for the water level necessary for

operation. The discharge end of the hose should be located higher

than the water surface. If the end of the hose is submerged, water may

flow back to the pump when the pump is stopped; and if the hose end

is lower than the water surface, water may overflow when the pump is

turned off.

3.3.2 The discharge connection is fitted with a 3/4-inch NPS coupling. Attach

a hose to the coupling and securely tighten the connection.

3.3.3 The hose should be run as straight as possible, since excessive

bending will hinder the water flow, preventing sufficient lift, and can

even cause the hose to become clogged with earth. If the hose is

crimped near the pump, air can become trapped in the pump and

cause idle running.

If large quantities of earth are sucked up, damage resulting from

friction in the pump can lead to electrical leakage and shock.

3.3.4 Use the pump in the upright position. To prevent the pump from

becoming submerged in mud, mount it on a block or other firm base if

necessary.

3.3.5 If used in a permanent installation, where the pump is not readily

accessible after installation, please contact Wacker Neuson for a

duplicate nameplate to be installed at the wellhead or on the control

box so that it will be readily visible.

3.4 Preparing for Installation

Before installing the pump at a work site, you will need to have the

following tools and instruments ready:

• Insulation resistance tester (megohmmeter)

• AC voltmeter

• AC ammeter (clamp-on type)

• Bolt and nut tighteners

• Power supply connection tools (screwdriver or box wrench)

Note: Please also read the instructions that come with each of the test

instruments.

CAUTION

Installation PSR1 500

16 wc_tx001978gb.fm

3.5 Checks to Make Before Installation

• When a grounded plug is used:

Use the megohmmeter to measure the insulation resistance between

the cable assembly prongs and ground.

• When connection leads are used:

With the megohmmeter, measure the insulation resistance between

each core lead and the ground lead.

Reference insulation resistance: 20MΩ or greater

Note: The reference insulation resistance (20M

Ω

or greater) is the

value when the pump is new or has been repaired. For the reference

value after installation, see “Periodic Maintenance Table.”

3.6 Electrical Wiring

Performing electrical wiring

Electrical wiring should be performed by a qualified person in accord

with all applicable regulations. Failure to observe this precaution not

only risks breaking the law but is extremely dangerous.

Incorrect wiring can lead to current leakage, electrical shock or fire.

Always make sure the pump is equipped with the specified overload

protectors and fuses or breakers, so as to prevent electrical shock from

a current leak or pump malfunction.

Operate within the capacity of the power supply and wiring.

Grounding

Do not use the pump without first grounding it properly. Failure to

ground it can lead to electrical shock from a current leak or pump

malfunction.

Do not attach the grounding wire to a gas pipe, water pipe, lightning

arrester or telephone grounding wire. Improper grounding can result in

electrical shock.

WARNING

CAUTION

PSR1 500 Installation

wc_tx001978gb.fm 17

3.7 Connecting the Power Supply

Before connecting leads to the terminal strip, make certain the power

supply is turned off (circuit breaker, etc.), to avoid electrical shock,

shorting, or unexpected starting of the pump, leading to injury.

Before inserting the power supply plug, make certain the power supply

is turned off (circuit breaker, etc.), to avoid electrical shock, shorting,

or unexpected starting of the pump, leading to injury.

Do not use the pump with the cable assembly or plug connected

loosely, which can result in electric shock, shorting, or fire.

Draw power from a dedicated power outlet rated at 15 A or above.

Sharing the outlet with other equipment may cause overheating at the

branch outlet and could result in fire.

NOTICE: Be sure to use a dedicated power supply with a ground

leakage circuit breaker.

Grounded plug

Connect only to receptacle of proper voltage and current rating

matching that of the plug provided with the cable assembly.

Without Plug

Tighten the ends of the cable assembly securely against the terminal

board. If installation of a grounded plug is required, use only a properly

rated and approved CEE plug and secure the ends of the cable

assembly securely to power and ground terminals in accordance with

the plug manufacturer’s instructions.

WARNING

CAUTION

RD

WH

L1

L2

GR

wc

_

gr004659

G

Installation PSR1 500

18 wc_tx001978gb.fm

3.8 Cable Assembly

If it is necessary to extend the cable assembly, use a core size equal

to or larger than the original. This is necessary not only to avoid a

performance drop, but to prevent cable overheating which can result in

fire, electrical leakage or electrical shock.

If a cable with cut insulation or other damage is submerged in the

water, there is a danger of damage to the pump, electrical leakage,

electrical shock, or fire.

Be careful not to let the cable assembly be cut or become twisted. This

may result in damage to the pump, electrical leakage, electrical shock,

or fire.

If it is necessary to submerge the connection wires of the cable

assembly in water, first seal the wires completely in a molded

protective sleeve, to prevent electrical leakage, electrical shock, or fire.

Do not allow the cable assembly wires or power supply plug to become

wet.

Make sure the cable does not become excessively bent or twisted, and

does not rub against a structure in a way that might damage it.

If used in a deep-well installation, the cable assembly should be

secured every 6 m (20 ft.).

CAUTION

PSR1 500 Operation

wc_tx001993gb.fm 19

4 Operation

4.1 Before Starting

4.1.1 Make sure once again that the product is of the correct voltage and

frequency rating.

NOTICE: Using the product at other than rated voltage and frequency

will not only lower its performance but may damage the product.

Note: Confirm the rated voltage and frequency on the model

nameplate.

4.1.2 Confirm the wiring, supply voltage, circuit breaker capacity, and motor

insulation resistance.

Reference insulation resistance = 20 MΩ or greater.

Note: The reference insulation resistance (20 MΩ or greater) is the

value when the pump is new or has been repaired. For the reference

value after installation see “Periodic Maintenance Table.”

4.1.3 The setting on the circuit breaker or other overload protector should be

made in accord with the rated current of the pump.

Note: See “Operating Specifications” for the rated current of the pump.

4.1.4 When powering the pump with a generator, be certain the generator is

sized to supply the required power for the pump and any other

equipment powered by the generator.

Test Operation

NEVER operate the pump while it is suspended in the air. The recoil

may result in injury or other major accident.

NEVER start the pump when people are standing next to it. A current

leak can result in electrical shock.

The pump will not start until the pump casing is wet. Before performing

a test operation or starting the pump when the remaining water level is

low, pour in clean water from the hose coupling. Approximately 2.5

liters (2.64 quarts) of priming water is required.

Run the pump for a short time (3–10 minutes) and confirm the

following:

• Using an ammeter (clamp-on type), measure the operating cur-

rent at the L1 and L2 phase wires on the terminal.

COUNTERMEASURE: If the operating current exceeds the rated

value, pump motor overload may be a cause. Make sure the pump has

been installed under proper conditions as described in Installation.

WARNING

Operation PSR1 500

20 wc_tx001993gb.fm

• Using an AC voltmeter (tester), measure voltage at the terminals.

Supply voltage tolerance: within ±5% of rated voltage.

COUNTERMEASURE: If the supply voltage is outside the tolerance,

possible causes are the power supply capacity or an inadequate

extension cable. Look again at the wiring diagram and make sure the

conditions are proper.

In case of very excessive vibration, unusual noise or odor, turn off the

power immediately and consult your nearest dealer or Wacker

representative. Continuing to operate the pump under abnormal

conditions may result in electrical shock, fire, or current leakage.

Operation

Make sure no extraneous objects such as pins, nails or other metal

objects are sucked into the pump. These can damage the pump or

cause it to malfunction, and can result in electrical shock or electrical

leakage.

When the pump is not used for an extended period, be sure to turn off

the power (circuit breaker, etc.). Deterioration of the insulation may

lead to electrical leakage, electrical shock, or fire.

In case of a power outage, turn off the power to the pump to avoid

having it start unexpectedly when the power is restored, presenting

serious risk of injury to people in the vicinity.

Always make sure the pump is primed before starting operation.

The pump may become hot during operation. Do not touch an

operating pump. Allow the pump to cool before handling.

Pay careful attention to the water level while the pump is operating. Dry

operation may cause the pump to malfunction.

Note: See topic “Operating Water Level” for the water level necessary

for operation.

If the protection system operates due to an overload or malfunction,

causing the pump to stop, disconnect the power supply to the pump.

Make sure that the power is completely shut off before proceeding.

Next, unplug the cable assembly from the receptacle or detach it from

the terminals. Then, investigate and remove the cause of the

malfunction before restarting the pump.

After stopping operation, detach the hose from the discharge

connector and turn the pump upside down to remove the water inside

the pump.

CAUTION

WARNING

CAUTION

WARNING

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